Pvc wall frame system

ABSTRACT

A system is provided for constructing a wall frame having a PVC stud, a PVC channel member, a groove formed in the PVC stud and a tongue formed in the PVC channel, wherein the tongue and groove are adapted to detachably couple the PVC stud and the PVC channel. The invention includes snap-on features that allow the components to be removably secured. The invention provides components that are constructed to eliminate insect infestation, rotting, shrinkage, warping and splintering.

CROSS-REFERENCE TO RELATED APPLICATION

This application is related to and claims priority to U.S. ProvisionalPatent Application Ser. No. 61/049,102, filed Apr. 30, 2008, entitledPVC WALL FRAMING SYSTEM, the entirety of which is incorporated herein byreference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

n/a

FIELD OF THE INVENTION

The present invention relates to plastic wall framing systems. Moreparticularly, the invention relates to PVC framing systems havingsnap-on components.

BACKGROUND OF THE INVENTION

Known framing systems include wood framing systems and metal framingsystems. These known framing systems are used to construct variousresidential and commercial building structures, including partitions.

Wood framing systems are widely accepted by the construction industry.Carpenters are familiar with wood frame construction and can nail woodframes together quickly with nail guns. In spite of the ease ofconstruction, wood framing systems have several drawbacks, includingabsorbing moisture; increasing fire risk; and increasing susceptibilityto insect infestation, rotting, shrinking, warping, and splintering;among other drawbacks. Additionally, the cost of purchasing lumbercontinues to increase.

Metal framing systems are less widely adopted than wood framing systems,but have found popularity in the commercial construction industry. Theconstruction industry is trade-oriented, so workers are less inclined toembrace the special training required to properly snip and cut the metalframe members. Additionally, metal screws are needed to construct themetal frames. Metal framing systems have several drawbacks, includingpoor thermal performance, poor sound performance and tendency to oxidize(e.g. rust), among other drawbacks.

SUMMARY OF THE INVENTION

The invention overcomes these drawbacks and other drawbacks of knownsystems by providing PVC framing systems having snap-on components. ThePVC framing systems may be used to construct various residential andcommercial building structures, including partitions. The PVC framingcomponents may include studs and tracks, angles, furring channels, andother PVC framing components.

According to one embodiment, the snap-on components may employ a tongueand groove configuration. For example, the tracks may include tongues,or protrusions, that engage grooves that are formed in the studs.Alternatively, the studs may include tongues, or protrusions, thatengage grooves that are formed in the tracks. As a result, no additionalhardware, such as nails, screws, or other hardware may be needed toconstruct the PVC frames. The snap-on feature reduces the amount of timeneeded to assemble PVC frames. The snap-on feature also reducesconstruction costs that otherwise would be associated with fastening thePVC frames, including the cost of the additional hardware (e.g., nails,screws, etc.) and the corresponding power tools (e.g., nail gun, screwgun, etc.).

According to one embodiment, the PVC framing components may be extrudedor injection molded into desired shapes. This allows the PVC framingcomponents to be formed as one piece components with features such ascrevices, holes, protrusions and other features. Additionally, theappearance of the PVC framing components may be modified using stains orpigments.

The PVC framing components provide several benefits over wood and/ormetal framing components. For example, the PVC components absorb littlemoisture; do not oxidize; may be manufactured to reduce fire risk and toeliminate insect infestation, rotting, shrinking, warping, andsplintering; among providing other benefits.

Furthermore, the PVC framing components are workable similar to woodframing components. Thus, end users may continue to use traditional woodworking techniques, tools, fasteners, etc., to construct the PVC framingsystems.

These and other features and advantages of the invention will beapparent through the detailed description of the embodiments anddrawings attached hereto. It is also to be understood that both theforegoing general description and the following detailed description areexemplary and not restrictive of the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and theattendant advantages and features thereof, will be more readilyunderstood by reference to the following detailed description whenconsidered in conjunction with the accompanying drawings, wherein likedesignations refer to like elements, and wherein:

FIG. 1 illustrates a perspective view of a stud and track assembly for anon-load bearing application according to one embodiment of theinvention;

FIG. 2A is a cross-sectional view of a stud for a non-load bearingapplication according to one embodiment of the invention;

FIG. 2B is a cross-sectional view of a track for a non-load bearingapplication according to one embodiment of the invention;

FIG. 3 illustrates a snap-on feature for a stud and track assemblyaccording to one embodiment of the invention;

FIG. 4 illustrates a perspective view of a stud and track assembly for aload bearing application according to one embodiment of the invention;

FIG. 5A is a cross-sectional view of a stud for a load bearingapplication according to one embodiment of the invention;

FIG. 5B is a cross-sectional view of a track for a load bearingapplication according to one embodiment of the invention;

FIG. 6 illustrates a snap-on feature for a stud and track assemblyaccording to one embodiment of the invention;

FIG. 7A illustrates a bridging strip in a non-engaged position forsecuring adjacent studs according to one embodiment of the invention;

FIG. 7B illustrates adjacent studs having openings for receiving abridging component according to one embodiment of the invention;

FIG. 8 illustrates a bridging strip in an engaged position for securingadjacent studs according to one embodiment of the invention;

FIG. 9 illustrates PVC hat channels that may be secured to trusses in aceiling or to a wall structure for anchoring a partition materialaccording to one embodiment of the invention;

FIG. 10 illustrates PVC furring strip that may be secured to masonrywalls for anchoring a partition material according to one embodiment ofthe invention.

DETAILED DESCRIPTION OF THE INVENTION

While specific embodiments of the invention are discussed herein and areillustrated in the drawings appended hereto, the invention encompasses abroader spectrum than the specific subject matter described andillustrated. As would be appreciated by those skilled in the art, theembodiments described herein provide but a few examples of the broadscope of the invention. There is no intention to limit the scope of theinvention only to the embodiments described herein. Like referencenumbers will be used herein to identify like elements.

FIG. 1 illustrates an embodiment of the PVC framing system 10 havingstuds 12 and a track 14. According to one embodiment, the studs 12 andthe track 14 may be constructed of a PVC material or other syntheticmaterial. The track 14 may be formed in a U-shaped geometry to includeprojections 15 that extend into cavity 16 from opposing inner sidesurfaces 13 of the track 14. While the projections 15 are illustrated tobe generally rectangular in shape, the projections 15 may be any shape,including wedge shape, circular shape, triangular shape, or any othershape. According to one embodiment, the projections 15 may be positionedalong a longitudinal direction “L” at spaced intervals along the track14. For example, the projections 15 may be positioned along thelongitudinal direction “L” at regular intervals of four inchescenter-to-center, six inches center-to-center, eight inchescenter-to-center, twelve inches center-to-center, etc.

FIG. 2A illustrates a cross-sectional view of the stud 12. The stud 12may include a C-shaped geometry and may include an opening 22 that runsalong one side of the stud 12 in a lengthwise direction. The opening 22may be provided to expose a hollow central portion 20 of the stud 12.According to one embodiment, the studs 12 may be designed havinggeometrical shapes that minimize the use of material to providelightweight studs. These lightweight studs may be used for non-loadbearing applications, such as providing a framing structure to hangdrywall or other partition forming material. According to oneembodiment, ribs may be formed on the stud 12 to increase load bearingcapacity. For example, ribs may be formed in an interior portion of thestud 12 to increase load bearing capacity. According to one embodiment,opposing grooves 24 may be formed on external surfaces of the stud 12 toreceive corresponding projections 15 from the track 14. According to oneembodiment, the stud 12 may include passages that enable objects, suchas electrical wires, plumbing pipes, and/or other objects, to passthrough the stud 12. One skilled in the art will readily appreciate thatthe studs 12 may be formed of different geometrical shapes withoutdeparting from the spirit of the invention.

FIG. 2B illustrates a cross-sectional view of the track 14. The track 14may include a U-shaped geometry and may include an opening that runsalong one side of the track 14 in a lengthwise direction. The openingmay be provided to expose a hollow central portion 26 of the track 14.According to one embodiment, ribs may be formed in the track 14 toincrease retention strength. Opposing projections 15 may be formed oninternal surfaces of the track 14 to engage corresponding grooves 24that are provided on the studs 12. Alternatively, projections may beformed along a bottom surface 27 of the track 14 to engage a bottomportion of the stud 12 in order to provide an enhanced structure toresist lateral movement of the stud 12. One skilled in the art willreadily appreciate that the track 14 may be formed of differentgeometrical shapes to receive the studs 12 without departing from thescope of the invention.

FIG. 3 illustrates an embodiment of the PVC framing system 10 whereinthe grooves 24 on the stud 12 are aligned with the projections 15 on thetrack 14. The stud 12 and the track 14 may be fastened together with asnapping mechanism. For example, a downward force may be applied to thestud 12 to securely snap the stud 12 onto the track 14. Once engaged,the stud 12 and track 14 may be mechanically coupled together. Accordingto one embodiment, the stud 12 and track 14 may be unlocked by applyingan upward force to the stud 12 in a direction away from the track 14.Other fastening mechanisms will be appreciated by those skilled in theart and are intended to be encompassed by the invention.

FIG. 4 illustrates a second embodiment of the PVC framing system 40having studs 42 and a track 14. According to one embodiment, the studs42 and the track 14 may be constructed of a PVC material or othersynthetic material. The track 14 may be formed in a U-shaped geometry toinclude projections 15 that extend into cavity 16 from opposing innerside surfaces 13 of the track 14. While the projections 15 areillustrated to be generally rectangular in shape, the projections 15 maybe any shape, including wedge shape, circular shape, triangular shape,or any other shape. According to one embodiment, the projections 15 maybe positioned along a longitudinal direction “L” at spaced intervalsalong the track 14. For example, the projections 15 may be positionedalong the longitudinal direction “L” at regular intervals of four inchescenter-to-center, six inches center-to-center, eight inchescenter-to-center, twelve inches center-to-center, etc.

FIG. 5A illustrates a cross-sectional view of the stud 42. The stud 12may include a rectangular shaped geometry. The center portion 50 of thestud 42 may be hollow. Alternatively, the center portion 50 of the stud42 may include reinforcing ribs to increase load bearing capacity of thestud 42. For example, the reinforcing ribs may be formed in an interiorportion of the stud 42 to increase load bearing capacity. According toone embodiment, the studs 42 may be designed having geometrical shapesthat minimize the use of material to provide lightweight studs. Thesereinforced lightweight rectangular studs 42 may be used for load bearingapplications, such as supporting weighted structures. According to oneembodiment, the studs 42 may include passages that enable objects, suchas electrical wires, plumbing pipes, and/or other objects, to passtherethrough. According to one embodiment, opposing grooves 24 may beformed on external surfaces of the stud 42 to receive correspondingprojections 15 from the track 14. One skilled in the art will readilyappreciate that the studs 42 may be formed of different geometricalshapes without departing from the spirit of the invention.

FIG. 5B illustrates a cross-sectional view of the track 14. The track 14may include a U-shaped geometry and may include an opening that runsalong one side of the track 14 in a lengthwise direction. The openingmay be provided to expose a hollow central portion 26 of the track 14.According to one embodiment, ribs may be formed in the track 14 toincrease retention strength. Opposing projections 15 may be formed oninternal surfaces of the track 14 to engage corresponding grooves 24that are provided on the studs 42. Alternatively, projections may beformed along a bottom surface 27 of the track 14 to engage a bottomportion of the stud 42 in order to provide an enhanced structure toresist lateral movement of the stud 42. One skilled in the art willreadily appreciate that the track 14 may be formed of differentgeometrical shapes to receive the studs 42 without departing from thescope of the invention.

FIG. 6 illustrates an embodiment of the PVC framing system 40 whereinthe grooves 24 on the stud 42 are aligned with the projections 15 on thetrack 14. The stud 42 and the track 14 may be fastened together with asnapping mechanism. For example, a downward force may be applied to thestud 42 to securely snap the stud 42 onto the track 14. Once engaged,the stud 42 and track 14 may be mechanically coupled together. Accordingto one embodiment, the stud 42 and track 14 may be unlocked by applyingan upward force to the stud 42 in a direction away from the track 14.Other fastening mechanisms will be appreciated by those skilled in theart and are intended to be encompassed by the invention.

FIG. 7A illustrates a bridging strip 70 having strip openings 72. FIG.7B illustrates studs 42 having stud openings 75 with stud projections76. The bridging strip 70 is designed to pass through the stud openings75 so that the stud projections 76 engage the strip openings 72.

FIG. 8 illustrates the bridging strip 70 in an engaged position forsecuring adjacent studs 42 according to one embodiment of the invention.The bridging strip 70 may be provided through the stud openings 75 sothat the strip openings 72 are mechanically coupled to the studprojections 76. The bridging strip 70 provides enhanced support to thePVC framing structure 40 by interlocking the studs 42. While the studprojections 76 are illustrated to be generally rectangular in shape, thestud projections 76 may be any shape, including wedge shape, circularshape, triangular shape, or any other shape. The stud projections 76 andthe bridging strip 70 may be fastened together with a snappingmechanism. For example, a downward force may be applied to the bridgingstrip 70 to securely snap the stud projections 76 into the stripopenings 72. Once engaged, the stud 42 and bridging strip 70 may bemechanically coupled together. According to one embodiment, the stud 42and the bridging strip 70 may be unlocked by applying an upward force tothe bridging strip 70. Other fastening mechanisms will be appreciated bythose skilled in the art and are intended to be encompassed by theinvention.

FIG. 9 illustrates a PVC hat channel 90 that may be secured to trussesin a ceiling or to a wall structure. FIG. 10 illustrates PVC furringstrip 100 that may be secured to masonry walls. The PVC hat channel 90and the PVC furring strip 100 may be provided to anchor a partitionmaterial, such as drywall or other partition material.

Once in place, the PVC framing system 10,40 may be used to mount apartition material, such as drywall or other partition material. Thepartition material may be mounted to the PVC framing structure usingtraditional wood screws. In this regard, the PVC material is workablelike wood. If needed, the PVC components may be cut using wood workingpower tools. Therefore, the invention provides a new technology thatwill be readily adopted by end users that are traditionally slow toadopt new technologies.

According to one embodiment, the invention provides improved soundtransmission, improved thermal efficiency and enhances environmentalperformance, as measured by Leeds guidelines for “green” construction.The invention enhances environmental performance by providingrecyclable, reclaimable and/or reusable products.

It will be appreciated by persons skilled in the art that the presentinvention is not limited to what has been particularly shown anddescribed herein above. In addition, unless mention was made above tothe contrary, it should be noted that all of the accompanying drawingsare not to scale. A variety of modifications and variations are possiblein light of the above teachings without departing from the scope andspirit of the invention.

1. A PVC stud system for constructing a wall frame, comprising: a PVCstud; a PVC channel member; a groove formed in the PVC stud; and atongue formed in the PVC channel, wherein the tongue and the groove areadapted to detachably couple the PVC stud and the PVC channel.